Volkswagen Golf 2004 Workshop Manual
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Volkswagen Golf 2004 Workshop Manual

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Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Passat 2006 ➤
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve)
Engine ID
Edition 02.2011
Service Department. Technical Information
AZV BKD BMN BKP BMA BVE BMR BUZ BWV

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Summary of Contents for Volkswagen Golf 2004

  • Page 1 Service Workshop Manual Golf 2004 ➤ Golf Plus 2005 ➤ Passat 2006 ➤ Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) AZV BKD BMN BKP BMA BVE BMR BUZ BWV Engine ID Edition 02.2011 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2011 Volkswagen AG, Wolfsburg K0058971620...

  • Page 3: Table Of Contents

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Contents 00 - Technical data ........... .
  • Page 4 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of lubrication system (Golf, Golf Plus, Touran) ......
  • Page 5 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing fuel gauge sender ........186 Checking fuel pump .
  • Page 6 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - silencer, vehicles with four-wheel drive ..... . 278 Cutting exhaust pipe .

  • Page 7: Technical Data

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 00 – Technical data Technical data Engine number ⇒ page 1 Engine data ⇒...
  • Page 8 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Engine code Turbo‐ charging/ supercharg‐ Charge air cooling Particulate filter Rep. gr.00 - Technical data...

  • Page 9: Removing And Installing Engine

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 10 – Removing and installing engine Removing and installing engine Removing engine ⇒ page 4 Securing engine to assembly stand ⇒...

  • Page 10: Removing Engine

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing engine Note Before carrying out further work, disconnect battery earth ♦ strap. First check whether a coded radio is fitted. Obtain anti- theft coding first if necessary.
  • Page 11 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove air filter housing with air mass meter and connecting pipe. Remove bolt -arrow A- and pull air filter housing upwards out of mounting.
  • Page 12 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Disconnect front exhaust pipe from turbocharger, loosen dou‐ ble clamp and slide exhaust pipe back ⇒...
  • Page 13 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Insert engine bracket -T10012- in engine and gearbox jack - V.A.G 1383/A- .
  • Page 14 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove bolt -arrow A- and pull air filter housing upwards out of mounting.
  • Page 15 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull off fuel supply hose -2-, fuel return hose -1- and coolant hose -3-.
  • Page 16 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Unscrew earth cable -arrow- from longitudinal member. – Move wiring clear. – Pull off or disconnect all other electrical connections from en‐...

  • Page 17: Securing Engine To Assembly Stand

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Unbolt pendulum support -arrows-. To facilitate removing and installing engine without opening re‐...
  • Page 18 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required ♦ Lifting tackle -2024 A- ♦ Workshop hoist -VAS 6100- ♦...

  • Page 19: Notes On Installing

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Attach lifting tackle -VAS 2024A- as follows and lift from engine and gearbox jack -V.A.G 1383/A- using workshop crane.

  • Page 20: Assembly Mountings

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Install insulation tray ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation .

  • Page 21: Crankshaft Group

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 13 – Crankshaft group Dismantling and assembling engine Note If large quantities of swarf or metal particles (caused, for example,...

  • Page 22: Removing And Installing Poly V-Belt

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing poly V-belt Special tools and workshop equipment required ♦ Locking pin -T10060 A- Removing –...
  • Page 23 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Belt drive without air conditioner compressor Belt drive with air conditioner compressor 1. Dismantling and assembling engine...

  • Page 24: Assembly Overview - Toothed Belt Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - toothed belt drive 1 - Toothed belt guard upper part 2 - Toothed belt ❑...
  • Page 25 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ Do not additionally oil or grease thread and shoulder. ❑ Turning further can be done in several stages.
  • Page 26 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate push-on connectors of fuel lines -arrows-. Note Do this by pressing in catch of push-on connectors.
  • Page 27 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove securing bolts from assembly mounting/engine sup‐ port -arrows- and remove complete assembly mounting.
  • Page 28 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Tighten bolts for engine support in the sequence shown -1…3- to 40 Nm + / 2 turn (180 °) further.

  • Page 29: Assembly Overview - Crankcase

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - crankcase 1 - Cylinder block ❑ Removing and installing sealing flange and fly‐...

  • Page 30: Removing And Installing Sealing Flange And Flywheel

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing sealing flange and flywheel Note Repairing clutch: ⇒ 6-speed manual gearbox 02Q; Rep. gr. 30 ;...

  • Page 31: Renewing Crankshaft Sealing Flange - Flywheel End

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 7 - 15 Nm 8 - Sealing flange with oil seal ❑ Removing and installing ⇒...
  • Page 32 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Rotate crankshaft as shown to TDC No. 1 cylinder. – Remove sump.
  • Page 33 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2.1.2 Pressing in sealing flange with sender wheel Note The sealing flange with a PTFE seal is equipped with a sealing ♦...
  • Page 34 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Clamp assembly device -T10134- in a vice on clamping sur‐ face -A- of threaded spindle.
  • Page 35 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Upper edge of sender wheel and front edge of sealing flange must align -arrows-.
  • Page 36 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-.
  • Page 37 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2.1.6 D - Pressing sender wheel onto crank‐ shaft flange using assembly tool - T10134- –...
  • Page 38 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Install engine speed sender -G28- -arrow- and tighten secur‐ ing bolt to 5 Nm.

  • Page 39: Renewing Crankshaft Oil Seal - Pulley End

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Renewing crankshaft oil seal - pulley end Special tools and workshop equipment required ♦...
  • Page 40 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Using great pressure, screw oil seal extractor as far as possi‐ ble into seal.

  • Page 41: Removing And Installing Sealing Flange - Pulley End

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing sealing flange - pulley end Special tools and workshop equipment required ♦...
  • Page 42 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove crankshaft toothed belt pulley. To do this, lock tooth‐ ed belt pulley using counterhold -3415- .

  • Page 43: Removing And Installing Engine Speed Sender G28

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Apply silicone sealant bead as shown to the clean sealing sur‐ face of sealing flange.
  • Page 44 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note If the securing bolt is a 5 mm Allen bolt (old version) use a com‐...

  • Page 45: Pistons And Conrods

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pistons and conrods Assembly overview - pistons and conrods ⇒ page 39 Piston and cylinder dimensions ⇒...

  • Page 46: Piston And Cylinder Dimensions

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ Insert bearing shells centrally. ❑ Check for secure seating. ❑ Axial clearance, wear limit: 0.37 mm ❑...
  • Page 47 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ End dimension plate -VW 385/17- ♦ Dial gauge Test procedure Piston projection at TDC must be measured when new pistons or a short engine is installed.

  • Page 48: Piston Rings, Cylinder Bore And Piston Installation Position

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Piston rings, cylinder bore and piston in‐ stallation position Checking piston ring gap Special tools and workshop equipment required ♦...
  • Page 49 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Cylinder bores must not be measured when the cylinder block is secured to engine and gearbox support -VAS 6095/1- with uni‐...

  • Page 50: Crankshaft

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Crankshaft Assembly overview - crankshaft ⇒ page 44 Crankshaft dimensions ⇒ page 44 Pulling needle bearing out of and driving into crankshaft ⇒...

  • Page 51: Pulling Needle Bearing Out Of And Driving Into Crankshaft

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Crankshaft main Conrod journal ∅ journal ∅ Basic dimension 54.00 -0.022 50.90 -0.022 -0.042...
  • Page 52 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing – Pull out using commercially available puller, e.g. Kukko 21/2 -arrow-, adapter -T10055/3- and puller -T10055- .

  • Page 53: Cylinder Head, Valve Gear

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 15 – Cylinder head, valve gear Cylinder head Assembly overview - cylinder head ⇒...
  • Page 54 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - Toothed belt guard upper part 2 - Toothed belt ❑ Mark direction of rota‐...

  • Page 55: Removing And Installing Cylinder Head Cover

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 20 - Tandem pump ❑ For fuel and vacuum supply. ❑ Check ⇒ page 225 ❑...
  • Page 56 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench -V.A.G 1331- Removing – Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.

  • Page 57: Removing, Installing And Tensioning Toothed Belt

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing, installing and tensioning toothed belt Note From 05.06 a modified engine support (with less clearance to en‐...
  • Page 58 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.3.1 Removing and installing toothed belt (vehicles with engine support with less clearance to engine)
  • Page 59 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Support bracket -10-222A- with adapters -10-222A/22- (for Golf, Golf Plus and Touran) or adapters -10-222A/1- (for Passat) ♦...
  • Page 60 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note From model year 2004, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole -arrow-. To tension and release toothed belt, use Allen key instead of pin wrench - T10020- .
  • Page 61 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Turn crankshaft until marking on crankshaft pulley and tooth seg‐ ments of camshaft pulleys are on top. Marking on toothed belt guard must align with camshaft sender wheel -arrows-.
  • Page 62 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove securing bolts from assembly mounting/engine sup‐ port -arrows- and remove complete assembly mounting.
  • Page 63 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Now turn pin-wrench clockwise to stop and tighten securing nut -1- hand-tight.
  • Page 64 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Now carefully turn tensioning roller clockwise using pin wrench until indicator is in middle of gap in base plate -arrow-.
  • Page 65 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.
  • Page 66 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Bolt engine assembly mounting to engine support -arrows- by bringing contact surfaces together using support bracket -10-222A- .
  • Page 67 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Locking tool -T10265- Removing Note Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
  • Page 68 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate push-on connectors of fuel lines -arrows-. Note Do this by pressing in catch of push-on connectors.
  • Page 69 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Now turn tensioning roller eccentric clockwise -arrow- onto stop and tighten securing nut -1- hand-tight.
  • Page 70 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Turn eccentric of tensioning roller clockwise -arrow- using special wrench, long reach -T10264- until indicator -2- is in middle of gap in base plate.
  • Page 71 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.

  • Page 72: Removing And Installing Cylinder Head

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing cylinder head Special tools and workshop equipment required ♦ Guide pins -3070- ♦...
  • Page 73 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench -V.A.G 1331- Note Before carrying out further work, disconnect battery earth ♦...
  • Page 74 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove air filter housing with air mass meter and connecting pipe. Remove bolt -arrow A- and pull air filter housing upwards out of mounting.
  • Page 75 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate vibration damper and remove it from crankshaft. Lock crankshaft at TDC No. 1 cylinder using crankshaft stop - T10050 bzw.
  • Page 76 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.4.2 Installing Note ♦ Always renew cylinder head bolts. In cases of repair carefully remove gasket remains from cyl‐...

  • Page 77: Checking Compression

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop -T10050 bzw. T10100- .

  • Page 78: Valve Gear

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Valve gear Note Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.
  • Page 79 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 13 - Exhaust roller rocker fingers ❑ Do not interchange used roller rocker fingers (mark).

  • Page 80: Removing And Installing Roller Rocker Finger

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installation position of mixture tube Notch in mixture tube faces upwards -arrow-. Checking camshaft axial clearance Special tools and workshop equipment required ♦...
  • Page 81 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2.2.1 Removing and installing exhaust roller rocker finger – Remove camshafts ⇒ page 79 –...

  • Page 82: Valves

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Valves 2.3.1 Valve dimensions Note Valves must not be reworked. Only lapping-in is permitted.
  • Page 83 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2.3.4 Renewing valve stem seals Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331/- ♦...
  • Page 84 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove valve springs using valve lever -VW 541/1A- and press tool -VW 541/6- .

  • Page 85: Removing And Installing Camshafts

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing camshafts Special tools and workshop equipment required ♦ Counterhold tool -T10051- ♦...
  • Page 86 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove bracket for exhaust gas recirculation cooler. – Remove toothed belt from camshaft pulleys ⇒...
  • Page 87 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Unscrew upper securing bolt -arrow- of bracket for bypass flap and exhaust gas recirculation cooler.
  • Page 88 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Evenly tighten bolts -1…20- as shown from inside to outside. Specified torque: 20 Nm –...
  • Page 89 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lock hubs using locking pin for diesel injection pump -3359- . – Install toothed belt and adjust valve timing ⇒...

  • Page 90: Removing And Installing Camshaft Oil Seal

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing camshaft oil seal Special tools and workshop equipment required ♦ Fitting tool -V.A.G 10-203- ♦...
  • Page 91 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lubricate threaded head of oil seal extractor -VAS 3240- , place it in position and while exerting firm pressure, screw it into oil seal as far as possible.

  • Page 92: Lubrication

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 17 – Lubrication Engine oil Note The oil level must not be above the max. mark - danger of damage to catalytic converter! Engine oil specifications - Golf, Golf Plus ⇒...

  • Page 93: Parts Of Lubrication System (Golf, Golf Plus, Touran)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of lubrication system (Golf, Golf Plus, Touran) Caution Finding metal shavings or a large quantity of small metal par‐...
  • Page 94 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 11 - Baffle plate 12 - 15 Nm 13 - 15 Nm 14 - Oil sump ❑...

  • Page 95: Removing And Installing Oil Sump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing oil sump Special tools and workshop equipment required ♦ Jointed wrench 10 mm - VAS 3185- ♦...
  • Page 96 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove sump. – Loosen sump with light blows of a rubber headed hammer if necessary.
  • Page 97 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Apply silicone sealing compound bead as shown to the clean sealing surface of the sump. (The figure shows the position of the sealant bead on the cylinder block.)

  • Page 98: Parts Of Lubrication System (Passat)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of lubrication system (Passat) Caution Finding metal shavings or a large quantity of small metal par‐...

  • Page 99: Assembly Overview - Oil Pump, Sump, Balancer Shaft Module With Chain Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - oil pump, sump, balancer shaft module with chain drive ⇒ page 93...
  • Page 100 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ Markings ⇒ page 86 8 - Guide tube ❑ For oil dipstick.

  • Page 101: Removing And Installing Oil Pump (For Balancer Shaft Module With Chain Drive)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 28 - Chain tensioner 29 - 20 Nm 30 - 10 Nm + / 4 turn (90°) further...
  • Page 102 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove cover securing bolts -arrows- and remove cover. – Push guide rail of chain tensioner in -direction of arrow- with a screwdriver and secure chain tensioner with pin -T10115- .
  • Page 103 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Install oil pump and tighten securing bolts -arrows- to correct specified torque:...

  • Page 104: Removing And Installing Balancer Shaft Module With Chain Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing balancer shaft module with chain drive Special tools and workshop equipment required ♦...
  • Page 105 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lock balancer shaft as shown using locking device -T10255- . Note When doing this the locking device -T10255- must engage in groove in balancer shaft -1-.
  • Page 106 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove securing bolts in sequence -8…1-. – Remove balancer shaft module. Installing Prerequisites •...

  • Page 107: Retrofitting Spur Gear Drive For Balancer Shaft Module

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Tighten securing bolts -1- and -3- to 10 Nm. – Carefully push guide rail of chain tensioner in -direction of arrow- with a screwdriver to relieve tension on chain tensioner.
  • Page 108 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦...
  • Page 109 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Position two-arm puller -T40001- with thrust plate -30 - 11- on drive sprocket of crankshaft journal as shown.

  • Page 110: Assembly Overview - Oil Pump, Sump, Balancer Shaft Module With Spur Gear Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - oil pump, sump, balancer shaft module with spur gear drive 1 - Oil sump ❑...
  • Page 111 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ When intermediate gear wheels are coated to areas around the circumference, a white spot is fitted to ensure correct installation position.
  • Page 112 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Oil spray jet and pressure relief valve Bolt with pressure relief valve, 27 Nm...

  • Page 113: Removing And Installing Oil Pump (For Balancer Shaft Module With Spur Gear Drive)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing oil pump (for balancer shaft module with spur gear drive) Removing –...

  • Page 114: Renewing Spur Gear For Crankshaft

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Crankshaft stop -T10100- for engines with oval crankshaft toothed belt pulley Procedure –...
  • Page 115 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Commercially available hotplate ♦ Fitting tool -10 - 203- ♦ Puller -T10392- ♦...
  • Page 116 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Insert puller -T10392- into holes of spur gear and turn clock‐ wise -arrow-, screw in locating pins -A-.

  • Page 117: Installing Balancer Shaft Module

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – When the temperature is reached, take spur gear up using pliers, as shown in illustration.
  • Page 118 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure Note The spur gear drive of the balancer shaft module must be in‐...
  • Page 119 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Position balancer shaft module on cylinder block, observe cor‐ rect position of partly coated intermediate gear wheel when doing this: •...
  • Page 120 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lock balancer shaft using locking tool -T10255- , turn balancer shaft if necessary.
  • Page 121 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Install lower toothed belt guard -arrows-. Remaining installation steps are carried out in reverse sequence;...
  • Page 122 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lock balancer shaft using locking tool -T10255- , turn balancer shaft if necessary.

  • Page 123: Removing And Installing Oil Sump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Install lower toothed belt guard -arrows-. Remaining installation steps are carried out in reverse sequence;...
  • Page 124 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Silicone sealant -D176404A2- ♦ Hand drill with plastic brush attachment ♦ Eye protection ♦...
  • Page 125 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Apply silicone sealing compound bead as shown to the clean sealing surface of the sump. (The figure shows the position of the sealant bead on the cylinder block.)

  • Page 126: Oil Filter Bracket, Oil Cooler, Oil Pressure And Oil Supply Line

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Oil filter bracket, oil cooler, oil pres‐ sure and oil supply line Assembly overview - oil filter bracket and oil cooler ⇒...

  • Page 127: Checking Oil Pressure And Oil Pressure Switch

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ See note. ❑ Coolant hose schematic diagram ⇒ page 131 ❑ Checking oil cooler for leaks ⇒...
  • Page 128 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Functional check and repair of the optical and acoustic oil pres‐ sure warning: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations 4.2.1...

  • Page 129: Assembly Overview - Oil Supply Line To Turbocharger

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - oil supply line to turbocharger 1 - Retaining clamp 2 - 25 Nm ❑...
  • Page 130 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installing Note The procedure must be followed to ensure that oil supply line is installed tension-free.

  • Page 131: Cooling

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 19 – Cooling Parts of cooling system WARNING When doing any repair work, especially in the engine compart‐...

  • Page 132: Parts Of Cooling System, Body Side

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of cooling system - body side ⇒ page 126 Parts of cooling system - engine side (Golf, Golf Plus, Touran) ⇒...

  • Page 133: Assembly Overview - Parts Of Cooling System, Engine Side (Golf, Golf Plus, Touran)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, Touran) 1 - To top of expansion tank.
  • Page 134 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ Note installation position ⇒ page 144 ❑ Checking: heat thermostat in water.

  • Page 135: Assembly Overview - Parts Of Cooling System, Engine Side (Passat)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - parts of cooling system, engine side (Passat) 1 - To top of expansion tank.
  • Page 136 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 21 - Connection ❑ For thermostat. ❑ Coolant hose schematic diagram ⇒ page 131 22 - Thermostat ❑...

  • Page 137: Coolant Hose Schematic Diagram

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Coolant hose schematic diagram Vehicles with manual gearbox ⇒ page 131 Vehicles with automatic gearbox ⇒...
  • Page 138 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.4.2 Vehicles with automatic gearbox 1 - Expansion tank 2 - Bypass flap 3 - Radiator ❑...
  • Page 139 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.4.3 Vehicles with dual clutch gearbox 1 - Expansion tank 2 - Bypass flap 3 - Radiator ❑...

  • Page 140: Draining And Filling Coolant

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Draining and filling coolant Special tools and workshop equipment required ♦ Refractometer -T10007- ♦...
  • Page 141 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull off lower coolant hose retaining clip -arrow- and remove coolant hose from quick-release connection of radiator.
  • Page 142 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Use only coolant additive G 12 plus-plus in accordance with ♦ TL VW 774 G.
  • Page 143 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Slowly fill coolant to upper marking of shaded field on expan‐ sion tank.
  • Page 144 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Use only coolant additive G 12 plus-plus in accordance with ♦ TL VW 774 G.

  • Page 145: Removing And Installing Fan Support With Fans

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Slowly fill coolant to upper marking of shaded field on expan‐ sion tank.

  • Page 146: Removing And Installing Radiator

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate connection -2- and free wiring. – Unclip connector -1- from fan support and move wiring clear.
  • Page 147 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing – Drain coolant ⇒ page 134 Golf, Golf Plus, Touran: – Bring lock carrier into service position ⇒ General body repairs, exterior;...

  • Page 148: Removing And Installing Coolant Pump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing coolant pump Special tools and workshop equipment required ♦ Refractometer -T10007- ♦...
  • Page 149 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump.

  • Page 150: Removing And Installing Thermostat

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing thermostat Special tools and workshop equipment required ♦ Jointed wrench 10 mm -3185- ♦...
  • Page 151 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Loosen securing bolts -4- of union -3- using T-bar and socket, 10 mm -3185- and remove using hexagon key extension, 5 mm -3249- and remove union -3- with thermostat -1-.

  • Page 152: Checking Cooling System For Leaks

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.10 Checking cooling system for leaks Special tools and workshop equipment required ♦ Cooling system tester - V.A.G 1274-...
  • Page 153 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/8- to expansion tank.

  • Page 154: Checking Oil Cooler For Leaks

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.11 Checking oil cooler for leaks Special tools and workshop equipment required ♦ Refractometer -T10007- ♦...
  • Page 155 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Cap -1J0 121 324- ♦ Coolant hose -251 265 056- Prerequisites: •...

  • Page 156: Fuel Supply System

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 20 – Fuel supply system Safety precautions Safety precautions when working on fuel supply system WARNING When doing any repair work, especially in the engine compart‐...

  • Page 157: Rules For Cleanliness

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Rules for cleanliness Rules for cleanliness when working on fuel supply system When working on the fuel supply and injection system, pay careful attention to the following „6 rules“...

  • Page 158: Parts Of Fuel Supply System (Golf, Golf Plus)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of fuel supply system (Golf, Golf Plus) Safety precautions ⇒ page 150 Rules for cleanliness ⇒...
  • Page 159 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 3.1.1 Assembly overview - fuel tank 1 - Cap 2 - 1.5 Nm 3 - Earth connection ❑...
  • Page 160 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece.
  • Page 161 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove fuel flap unit. ⇒ General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit –...

  • Page 162: Fuel Tank, Vehicles With Four-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Fuel tank, vehicles with four-wheel drive 3.2.1 Assembly overview - fuel tank 1 - Supply line ❑...
  • Page 163 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 12 - Fuel gauge sender 2 -G169- 13 - Fuel tank ❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
  • Page 164 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Before disconnecting battery, open fuel tank flap and if necessary remove wheel lock adapter from luggage compartment.
  • Page 165 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull off adapter cable on four-wheel drive control unit -J492- . – Support fuel tank using engine and gearbox jack -V.A.G 1383 A- and unscrew tensioning straps and securing bolts.
  • Page 166 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Fit adapter cable on four-wheel drive control unit -J492- . The remaining installation steps are carried out in the reverse se‐...
  • Page 167 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull fuel gauge sender 2 -G169- upwards slightly and unclip it from the suction-jet pump.

  • Page 168: Emptying Fuel Tank

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull return hose of suction-jet pump out of fuel delivery unit -arrow-.
  • Page 169 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .

  • Page 170: Removing And Installing Fuel Delivery Unit

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull connector and fuel lines off flange. Note Press buttons on hose couplings to do this.
  • Page 171 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Fold rear seats forwards. – Detach carpet under seats and fold it back. ⇒ General body repairs, interior;...

  • Page 172: Removing And Installing Fuel Gauge Sender

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing fuel gauge sender Removing – Remove fuel delivery unit ⇒ page 164 –...
  • Page 173 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate quick release coupling -A- (black or black marking) of fuel supply line.
  • Page 174 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate quick release coupling -A- (black or black marking) of fuel supply line.
  • Page 175 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Test instrument adapter/DSO (5-pin) -VAS 5565- Test prerequisites • Fuses must be OK.
  • Page 176 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Connect hand-held multimeter -V.A.G 1526D- to contacts -1- and -5- of adapter.

  • Page 177: Assembly Overview - Fuel Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull connector -C- off flange. – Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit.
  • Page 178 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - Supply line ❑ From fuel tank. ❑ White or with white marking.

  • Page 179: Removing And Installing Fuel Cooler

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 3.7.1 Fuel filter upper part Type A ⇒ page 173 Type B ⇒ page 173...
  • Page 180 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note The fuel cooler is located in the return line to tank. It is located on the vehicle underbody.

  • Page 181: Parts Of Fuel Supply System (Touran)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of fuel supply system (Touran) Note Hose connections are secured with either spring-type or ♦...

  • Page 182: Assembly Overview - Fuel Tank With Attachments

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Safety precautions ⇒ page 150 Rules for cleanliness ⇒ page 151 Assembly overview - fuel tank with attachments ⇒...

  • Page 183: Emptying Fuel Tank

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 13 - Seal ❑ Renew. ❑ Moisten with fuel when installing. 14 - Union nut, 80 Nm ❑...
  • Page 184 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Union nut tool -3217- ♦ Torque wrench (40…200 Nm) -V.A.G 1332- – Note safety precautions before starting work ⇒...
  • Page 185 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove filler cap from fuel tank filler neck. – Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck.

  • Page 186: Removing And Installing Fuel Tank

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Open locking ring using union nut tool -3217- . – Lift fuel delivery unit.
  • Page 187 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim;...

  • Page 188: Assembly Overview - Fuel Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - fuel filter 1 - Fuel filter upper part ❑ Observe various types ⇒...

  • Page 189: Removing And Installing Fuel Cooler

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 4.4.1 Fuel filter upper part Type A ⇒ page 183 Type B ⇒ page 183...

  • Page 190: Removing And Installing Fuel Delivery Unit

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note The fuel cooler is located in the return line to tank. It is located on the vehicle underbody.
  • Page 191 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐...

  • Page 192: Removing And Installing Fuel Gauge Sender

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing fuel gauge sender Removing – Remove fuel delivery unit ⇒ page 184 –...
  • Page 193 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate quick release coupling -A- (black or black marking) of fuel supply line.
  • Page 194 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Separate quick release coupling -A- (black or black marking) of fuel supply line.
  • Page 195 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Test instrument adapter/DSO (5-pin) -VAS 5565- Test prerequisites • Fuses must be OK.
  • Page 196 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Connect hand-held multimeter -V.A.G 1526D- to contacts -1- and -5- of adapter.
  • Page 197 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull connector -C- off flange. – Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit.

  • Page 198: Parts Of Fuel Supply System (Passat)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of fuel supply system (Passat) Safety precautions ⇒ page 150 Rules for cleanliness ⇒...
  • Page 199 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 9 - Breather line ❑ Clipped onto fuel tank. ❑ Check for secure seating.
  • Page 200 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169- The marking on the flange must align with the marking on the fuel tank -arrow-.
  • Page 201 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull 5-pin connector -arrow- off flange. Note For vehicles with auxiliary heater the metering pump -V54- con‐...
  • Page 202 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Unbolt filler neck from body -arrows-. – Remove front left and right underbody panels from underbody.
  • Page 203 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Unclip brake lines -arrow- on left from body. – Support rear axle using engine and gearbox jack -V.A.G 1383 A- .
  • Page 204 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Raise fuel tank slowly up to installation position and secure it in place.
  • Page 205 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench (40…200 Nm) -V.A.G 1332- Removing Prerequisites: • Fuel tank must not be more than / 2 full.
  • Page 206 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Open locking ring using wrench -T10202- . – Pull fuel gauge sender 2 -G169- upwards slightly and unclip locking lugs -arrows- of suction-jet pump.
  • Page 207 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Observe installation position of cover -B-: The -arrow- on the cover points forwards.

  • Page 208: Emptying Fuel Tank, Vehicles With Four-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing suction-jet pump Note Note safety precautions before beginning work ⇒ page 150 ♦...
  • Page 209 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Note safety precautions before beginning work ⇒ page 150 Emptying fuel tank if it is more than / 4 full ⇒...
  • Page 210 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 WARNING Fuel supply line is pressurised. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connec‐...
  • Page 211 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Open locking ring using wrench -T10202- . – Lift flange. – Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel.

  • Page 212: Fuel Tank, Vehicles With Front-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Fuel tank, vehicles with front-wheel drive 5.3.1 Assembly overview - fuel tank 1 - Cap 2 - 1.5 Nm...
  • Page 213 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 15 - Suction-jet pump ❑ Clean strainer if soiled. ❑ Not necessarily installed 16 - Flange ❑...
  • Page 214 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench (5…50 Nm) -V.A.G 1331- ♦ Engine and gearbox jack -V.A.G 1383/A-...
  • Page 215 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull 5-pin connector -5- off fuel delivery unit flange. – Open fuel tank filler flap.
  • Page 216 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove securing bolts -arrows- and lower rear axle. – Then support fuel tank using engine and gearbox jack -V.A.G 1383 A- .
  • Page 217 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench (40…200 Nm) -V.A.G 1332- Removing – Note safety precautions before beginning work ⇒...
  • Page 218 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull fuel line -1- off suction-jet pump (if fitted). Note Press in securing ring to release fuel line.

  • Page 219: Emptying Fuel Tank, Vehicles With Front-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Release connector tabs of wires -arrows- and pull them off. – Lift up retaining tabs -1- using a screwdriver and pull off fuel gauge sender upwards in -direction of arrow-.
  • Page 220 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Use insulating tape to mark the extraction hose -arrow- at a distance of -a- = 990 mm from the end of the hose.

  • Page 221: Checking Fuel Pump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Open locking ring using fuel tank sender wrench -3087- . – Lift sender flange.
  • Page 222 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 5.5.2 Checking fuel pump delivery rate Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550- ♦...
  • Page 223 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull fuel supply line (black, or black marking) -A- off fuel de‐...
  • Page 224 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Connect test instrument adapter/DSO (5-pin) -VAS 5565- be‐ tween connector and flange.

  • Page 225: Assembly Overview - Fuel Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull connector -C- off flange. – Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit.
  • Page 226 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - Return line ❑ To fuel cooler ❑ Check for secure seat‐...

  • Page 227: Removing And Installing Fuel Cooler

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 5.6.1 Fuel filter upper part Type A ⇒ page 221 Type B ⇒ page 221...
  • Page 228 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note The fuel cooler is located in the return line to fuel tank. It is located on the vehicle underbody.

  • Page 229: Accelerator Mechanism

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Accelerator mechanism Assembly overview - accelerator mech‐ anism Removing and installing accelerator mechanism ⇒...
  • Page 230 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Torque wrench (5…50 Nm) -V.A.G 1331- Removing – Lever off cap ⇒ Item 4 (page 223) using a screwdriver.

  • Page 231: Tandem Pump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Tandem pump Checking tandem pump ⇒ page 225 Removing and installing tandem pump ⇒...
  • Page 232 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Connect tandem pump tester -VAS 5187- if necessary, with adapter -VAS 5187/7- or banjo bolt with seal -VAS 5187/1A- as shown.

  • Page 233: Removing And Installing Tandem Pump

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure – Pull fuel supply hose (white marking) and fuel return hose (blue marking) off tandem pump.
  • Page 234 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Hand vacuum pump with accessories -V.A.G 1390-...
  • Page 235 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull vacuum line -1- off tandem pump -4-. – Pull supply hose -2- (white marking) and return hose -3- (blue marking) off tandem pump -4-.

  • Page 236: Turbocharging/Supercharging

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 21 – Turbocharging/supercharging Charge air system with turbocharger Safety precautions ⇒ page 230 Rules for cleanliness ⇒...

  • Page 237: Hose Connections

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ When system is open: do not work with compressed air if this can be avoided.

  • Page 238: Assembly Overview - Turbocharger With Attachments

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.3.2 Hose connections with spring band ring Note There is a danger of a „hose detaching“ whilst driving after re‐...
  • Page 239 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Observe rules for cleanliness ⇒ page 230 Observe safety precautions ⇒ page 230 1 - Seal ❑...
  • Page 240 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 20 - Heat shield 21 - 20 Nm 1.4.2 Engine codes BMN, BMR and BUZ Note All hose connections are secured.

  • Page 241: Removing And Installing Turbocharger

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 11 - 25 Nm ❑ Renew. 12 - Connecting pipe ❑ To exhaust gas recirculation cooler 13 - Seal ❑...
  • Page 242 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Caution When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger.

  • Page 243: Assembly Overview - Charge Air Cooling

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - charge air cooling Note When making repairs, remove oil from connection and hose ♦...

  • Page 244: Checking Charge Air System For Leaks

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.6.2 Engine codes BMN, BMR and BUZ Assembly of hose connections ⇒ page 231...
  • Page 245 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove intake hose -1- from air filter. – Connect adapter -1687/10- in intake hose -1- and secure with clip.

  • Page 246: Vacuum Hose Schematic Diagram

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- .
  • Page 247 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.8.2 Engine codes BMN, BMR and BUZ 1 - Air filter 2 - Charge pressure control...

  • Page 248: Mixture Preparation - Injection

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 23 – Mixture preparation - injection Diesel direct injection system Note The diesel direct injection system control unit -J248- is equipped with a fault memory.

  • Page 249: Rules For Cleanliness

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ If the engine is to be turned at starter speed, without starting, e.g.

  • Page 250: Assembly Overview - Intake Manifold With Attachments

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - intake manifold with attachments Engine codes AZV, BKD, BKP, BMA, BVE and BWV ⇒...
  • Page 251 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.3.2 Engine codes BMN, BMR and BUZ 1 - 10 Nm 2 - Retainer...

  • Page 252: Assembly Overview - Pre-Wired Wiring Harness For Unit Injectors And Glow Plugs

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs 1 - Glow plug connector 2 - Stainless steel clips ❑...
  • Page 253 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Special wrench -T10310- Removing Caution Removal and installation of the pre-wired wiring harness may only be undertaken by unscrewing the clips.
  • Page 254 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Pull the securing clip -1- upwards lightly with a screwdriver and press the central connector -2- through inwards.

  • Page 255: Assembly Overview - Unit Injector

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Fit adapter ring (colour marked „longer“ stud -arrow- faces 12 o'clock) – Fit special wrench -T10310- on adapter ring and lock it by turning key through 90°...
  • Page 256 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 3 Nm + 90 ° (1/4 turn) further + 180° (1/2 turn) further ❑...

  • Page 257: Removing And Installing Unit Injector

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing unit injector Special tools and workshop equipment required ♦ Universal dial gauge brack‐...
  • Page 258 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Valve lever -VW 541/1 A- with press tool -VW 541/5- ♦ Torque wrench -V.A.G 1783- Removing –...
  • Page 259 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Insert puller -T10163- in bolt holes on unit injector. – Turn spindle -A- down lightly onto the unit injector. Hand-tight‐...
  • Page 260 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Fit the new securing bolts and carefully screw in by hand onto stop -arrow- without force.

  • Page 261: Cleaning Unit Injectors (Engine Codes Bmn, Bkp, Bma, Buz And Bmr)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Turn adjustment screw 180° back off stop. – Hold adjuster screw in this position and tighten lock nut to 30 –...
  • Page 262 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Set mounting plate for unit injectors -VAS 6418/3- onto clean‐ ing unit.

  • Page 263: Removing And Installing O-Rings For Unit Injector

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing O-rings for unit injector For unit injectors with solenoid valve: Special tools and workshop equipment required ♦...
  • Page 264 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Slide assembly sleeve -T10164/1- or assembly sleeve - T10308/1- onto stop on unit injector.

  • Page 265: Assembly Overview - Air Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1.10 Assembly overview - air filter 1 - Intake hose ❑ To turbocharger.

  • Page 266: Engine Control Unit (Golf)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Engine control unit (Golf) Removing and installing engine control unit ⇒ page 260 Removing and installing anti-theft engine control unit ⇒...
  • Page 267 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Hot air blower from wiring harness repair set -VAS 1978- Note If the engine control unit is to be renewed, connect vehicle ♦...
  • Page 268 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note If the bolts will not move, saw into heads of shear-head bolts so that two parallel slots are created -arrows- and then remove the bolts.
  • Page 269 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Press catch -1- against engine control unit. – Push protective housing onto bracket.

  • Page 270: Engine Control Unit (Golf Plus, Touran)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Engine control unit (Golf Plus, Tour‐ Removing and installing engine control unit ⇒ page 264 Removing and installing anti-theft engine control unit ⇒...

  • Page 271: Removing And Installing Anti-Theft Engine Control Unit

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Tighten securing nuts -arrows- to 10 Nm. – Fit connector and lock in position.
  • Page 272 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Turn temperature settings potentiometer -2- to a maximum heat output of 600 °C.
  • Page 273 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Tighten securing bolts -arrows- to 10 Nm. – Install cover of protective housing.

  • Page 274: Engine Control Unit (Passat)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Engine control unit (Passat) Removing and installing engine control unit ⇒ page 268 Removing and installing anti-theft engine control unit ⇒...

  • Page 275: Removing And Installing Anti-Theft Engine Control Unit

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Slide engine control unit -1- into retaining frame in -direction of arrow-.
  • Page 276 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing – Switch off ignition. – Remove wiper arms ⇒ Rep. gr. 92 .
  • Page 277 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Lift cover -1- and pull it forwards. – Slide connector locking devices -1- on engine control unit out‐...
  • Page 278 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Fit connector to engine control unit and slide locking devices -1- inwards.

  • Page 279: Exhaust System

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 26 – Exhaust system Front exhaust pipe Note Removing and installing exhaust manifold ⇒...

  • Page 280: Assembly Overview - Front Exhaust Pipe With Particulate Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - front exhaust pipe with particulate filter Note Removing and installing exhaust manifold ⇒...
  • Page 281 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 8 Nm 2 - Exhaust gas pressure sen‐ sor 1 -G450- 3 - Retainer ❑...
  • Page 282 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 18 - 40 Nm 19 - Retainer ❑ Bolted to cylinder head. Rep. gr.26 - Exhaust system...

  • Page 283: Silencer (Golf, Golf Plus)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Silencer (Golf, Golf Plus) Assembly overview - silencer, vehicles with front-wheel drive Note Removing and installing exhaust manifold ⇒...

  • Page 284: Assembly Overview - Silencer, Vehicles With Four-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 9 - Front silencer ❑ For repairs, renew indi‐ vidually. 10 - Clamp Specified torque and installation position ⇒...

  • Page 285: Installation Position And Specified Torque Of The Clamp

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ♦ Pneumatic sabre saw -V.A.G 1523/A- – Cut exhaust pipe at right angles at separating point -A-.

  • Page 286: Aligning Exhaust System Free Of Stress

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installation dimension -a- for vehicles with marking on front ex‐ haust pipe 1 - Clamp...
  • Page 287 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Push rear silencer forwards into clamp until dimension -a- = 15…17 mm is attained between mounting attachment points for body and rear silencer.

  • Page 288: Silencer (Touran)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Silencer (Touran) Assembly overview - silencers Note After working on the exhaust system ensure that the system ♦...

  • Page 289: Cutting Exhaust Pipe

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Cutting exhaust pipe Special tools and workshop equipment required ♦ Pneumatic sabre saw -V.A.G 1523/A- –...

  • Page 290: Silencer (Passat)

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Silencer (Passat) Assembly overview - silencer, vehicles with front-wheel drive 1 - From front exhaust pipe 2 - Clamp ❑...

  • Page 291: Assembly Overview - Silencer, Vehicles With Four-Wheel Drive

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - silencer, vehicles with four-wheel drive 1 - Clamp ❑ Before tightening, align...
  • Page 292 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Push front and rear silencer into clamp until dimension -a- (4 mm) is attained between mounting attachment points for body and rear silencer.

  • Page 293: Exhaust Gas Recirculation System

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Exhaust gas recirculation system Assembly overview - parts of exhaust gas recirculation ⇒ page 287 Schematic diagram of vacuum hoses ⇒...
  • Page 294 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 22 Nm 2 - Connecting pipe 3 - Seal ❑ Renew.
  • Page 295 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 20 Nm 2 - Connecting pipe 3 - Seal ❑ Renew.

  • Page 296: Glow Plug System

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 28 – Glow plug system Optical characteristics of metal or ce‐ ramic glow plugs...
  • Page 297 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure Note Do not cant glow plugs when removing and installing. Remove any components hindering assembly.

  • Page 298: Removing And Installing Ceramic Glow Plugs

    Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing and installing ceramic glow plugs Special tools and workshop equipment required ♦ Special wrench, long reach -T50001- ♦...
  • Page 299 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 – Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.

This manual is also suitable for:

Golf plus 2005Passat 2006Touran 2003

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